Transcript Document

TPM, Total Preventative
Maintenance
Total Productive Maintenance AKA
What is it? A total system of maintenance covering all major
equipment.
What are the Benefits?
• TPM is a tried and tested way to eliminate the Six Big
Losses. This saves money and makes you’re factory a
better places to work.
• It gives you, the Operator, the knowledge and confidence
to manage your own machines.
• TPM is a long term process to increase skills, raise
efficiency and achieve minimal downtime on the machine.
Having no TPM on your equipment
can lead to the Six Big Losses
Equipment
Six Big Losses
1
Breakdowns
Total Running time
of your machine is
affected by :
The Available Time is cut
dramatically by the
Six Big Loss
These Losses Can be
Eliminated Easily And
Painlessly
Action
2
3
Idling / minor
stoppages
4
5
Setup /
adjustment
Speed
Defects
and rework
6
Start up losses
If your Machine has no TPM then raise the issue
KPIs & Performance Boards
AKA
Metrics, KPIs,
Performance Management
What is it? To compete as a Business we must always be
improving. KPIs and Performance Boards are a structured,
visual approach to reviewing and improving performance.
What are the Benefits?
• Highlights issues & allow us to react to them.
• Gives us an Indication where improvement is needed.
• Make the performance in all areas visible to all.
• Lets you see how your department is performing.
How can you improve if you
don’t know where you are?
Data
This data tells us
whether we have
improved!
Improvement
Information
To know where you
are you need data!
Measurement
To get data,
you need to measure!
•How are We Performing?
•How are They Performing?
•How are You Performing?
•How can I Perform better?
If you don’t know how you are Performing how do
Action
you know that you need to Improve? Ask!
FMEA
AKA
Failure Mode Effects
Analysis
What is it? Introducing New Processes and Products
can be risky! FMEAs identify potential Failures and their
causes before they happen.
What are the Benefits?
• Prioritises potential Failures according to their Risk
• Drives improvement actions to eliminate or reduce the
problem from happening
• Provides a documented & structured way of capturing
data & action
This is the template we use to create our FMEA’s
All areas must be completed to look at the possible
risk for this changed Process or Product type.
If you are introducing a New Process or Product,
Action you will benefit from carrying out an FMEA – Ask!
Standard Ops
Standard Operating
Procedures, SOPs,
AKA
What is it?
Identifying the best way to do something
leads to efficiency and business Improvement. Everyone
following that same method gives us Control and Safe
Working. Standard Ops define this Method of Working.
What are the Benefits?
•Gives you a consistent way of operating
•Ensures you follow defined manufacturing processes
A stepped approach to
Operating
standardising the way
a Standard
we all work
Procedure
6. Roll Out to Team
Creating
5. Document Best Method
Steps to
The Six
4. Test Methods
3. Develop Best Method
2. Record Data
1. Select Operation
Document Number
SOP 10
No.
1
STANDARD OPERATING
PROCEDURE
MAJOR STEP
INSERT RUN ON AND SECURE WITH RIGHT
CLAMP
2
PRE-FORM BOTH SIDES OF STRIP (lengths
greater than 20"pre form one side at a time)
3
INSERT LEFT SIDE OF STRIP AND CLAMP
4
RELEASE RIGHT CLAMP
5
INSERT RIGHT SIDE OF STRIP AND CLAMP
6
REMOVE BURRS FROM RUN OFF AND WIPE
CLEAN
7
INSERT RUN OFF AND APPLY MINIMAL
PRESSURE
8
PRESS CYCLE START
9
UNCLAMP BOTH SIDES
10
REMOVE AND INSPECT PART
11
SNIP RUN ON / RUN OFF AND INSPECT PART
AREA
PROCESS
MACHINE
ISSUE DATE
ISSUE No.
ORIGINATOR
CHECKED
RMS
Plasma ButtWelding
W4
24.06.2005
1
G Fletcher
D Roberts
KEY POINT REASON:
KEY POINT
Saf ety
Quality
PHOTO / SKETCH
Ease
Ensure leading edge of run on is burr side up and pushed
firmly against the stop (see fig.1).
Incorrect alignment will cause a weld spoil.
Ensure pre-form is a smooth radius, not a sharp corner.
Internal parts: burrs on inside
External parts: burrs on outside
Ensure end of strip is aligned with centre of slot in backing
bar (see fig.2).
Ensure the strip is pushed firmly against the run on.
No more than 1 turn is necessary.
Sharp corners will not roll out.
Ensure the strip is pushed firmly against the run on.
Ensure ends of strip are pushed firmly together.
Any gap will cause a spoil.
Any gap will cause a spoil.
Lead edge only need be deburred.
Unnecessary processing: 7 Wastes.
Ensure leading edge of run off is burr side up and pushed
firmly against the strip (see fig.3).
Any gap will cause a spoil.
Excessive pressure could cause cuts to the hands.
No more than 1 turn is necessary.
Unnecessary processing: 7 Wastes.
Inspect both sides of weld under magnification.
To ensure weld satisfies the required standard.
Visually inspect to ensure part is not damaged with snips.
Will cause a spoil.
Fig. 1
Ensure run on is burr
side up and firmly
against the stop.
Incorrect alignment will cause a weakened weld.
Any gap will cause a spoil.
Fig. 2
Ensure end of strip is
aligned with centre of
slot in backing bar.
Fig. 3
Ensure run off is burr
side up and firmly
against the strip.
12
13
14
EYE PROTECTION
EAR PROTECTION
FOOT PROTECTION
HEAD PROTECTION
HAND PROTECTION
PPE REQUIRED:
(Specify)
All key processes should have a standard
Action operation procedure. If not ask!
RESPIRATORY
PROTECTION
OTHER PPE:
Pareto
AKA
80/20,
What is it? We want to Improve, but there’s so much to
do, and limited time available. A pareto chart can show
where the biggest issues are.
What are the Benefits?
• Easy to see where the biggest problems are
• Will allow you to focus on the real problems
• Easy to use & understand
• Is used by all organisations
This is the area the team
would focus it’s efforts first!
We should Act on Fact, not Opinion.
Reviewing Evidence allows us to Choose
What to Focus on!
Action
With Pareto you should always target the largest
portions of the chart first
Fishbone
AKA
Nicholsons 6M, Cause &
Effect, Ishikawa &
Fishbone diagram
What is it? A fishbone diagram is used to organise ideas
about the potential causes of a problem.
What are the Benefits?
• Fishbone diagrams help separate a large problem into
manageable pieces.
• A team method is used to solve the problem.
• It can also help you visualize relationships between a
problem and possible underlying causes.
Brainstorm the Teams Ideas
Organise the Teams Ideas
NST Business Project
Measurements
Material
Man
excessive set up
shape of seal
not the right amount of shims
where is the micrometer
material may be warped and
out of shape
where is the vernier
over measuring of heights
person may be ill
heat treated parts not
flattening
getting enough 0.020" shims
no stand to hold parts
height of ram too high in the
press
waiting for hydraulic press
press needs to be reset
shims need to be moved
around to get correct height
having to clean oil leaks
both presses flattening together
(not enough shims)
where is the box of shims
die's not level
press out of order
time it takes to measure shims
climate in factory (too hot)
Action
press being used for other jobs (2)
size of parts
shims moving in press (2)
searching for correct shims
Mother Nature
Excessiv e
flattening
time
Methods
speed of the press (2)
Machines
When carrying out a brainstorming session with
your team always use the fishbone diagram!
PDCA
AKA
Plan, Do, Check, Act
What is it? Plan Do Check Act (PDCA) is a set of steps
that provides an approach to problem solving and
continuous improvement.
What are the Benefits?
• A structured way of carrying out a project
• Uses a standard stepped method for completing the
project
• Simple and easy to follow
• Goals for the project are always set out at the start
The P.D.C.A Cycle
1. Select
Project
12. Continuous
Improvement
11. Monitor
Solution
3. Set Goals
ACT
10. Implement
Solution
8. Test
Solutions
Action
PLAN
Continuous
Improvement
Cycle
CHECK
9. Ensure
Goals are
satisfied
2. Explain
Reason
DO
7. Develop
Solutions
4. Prepare
Action Plan
5. Gather the
data
6. Analyse the
facts
For Projects always use the PDCA cycle!
7 Wastes
AKA
7 W or 8W
What is it? Removing or minimising any function or
operation that can allow any of the below to happen.
What are the Benefits?
•Will increase time spent producing parts that our
customers pay for and want in the best method possible
Illustrate!
Over-production
Not Right First Time –
Scrap, Rework & Defects
1
Inventory
7
2
WASTE
Over-processing 6
3
5
Transportation
IN
Motion
4
Waiting
OUT
There is a 8th Waste not utilising you!
Action If you see any of these in your area think of how
you can reduce or eliminate it.
5C
AKA
5S
What is it? A easy to follow step by step approach to
creating and sustaining a productive workplace
What are the Benefits?
• Gives you the opportunity to design your work area
• Removes items within your area you don’t need
• Makes it easy to locate the tools you need to do your job
• Makes it easy to identify when equipment is missing
• Makes it easy to identify when equipment is broken
• Makes all of the above sustainable
Before
After
activity
a 5C
and complete
Adherence to the system rules!! and build
in further improvements
to carryout
The steps
Custom & Practice
Conformity
Consolidate the previous 3C’s, standardisation,
and use of Visual Management to Control
Clean and Check
Identify cleaning zones, establish cleaning routines
involving the whole team (inc Maintenance)
Configure
A specific place for specific items
“A place for everything & everything in its place”
Clearout and Classify
Major clean down and classify tools based on production
usage
Action
If your work areas is out of control you need to
“5C”
5 Why
AKA
Route cause analysis
What is it? The practice of asking “WHY”, five times, why
the failure has occurred in order to get to the root cause or
causes of the problem.
What are the Benefits?
• It helps to quickly determine the root cause of a problem
• It is easy to learn and apply
1
2
3
Q : WHY has machine stopped ? Q : WHY overload trip ? Q : WHY Insufficient oil ?
A : Overload tripped out !
A : Insufficient oil on shaft ! A : Oil pump in efficient !
4
5
Q : WHY is pump not efficient ? Q : WHY is this shaft worn ?
A : Pump drive shaft worn ! A : Oil filter blocked with swarf !
Root-cause
Action If you have a problem ask “why” five times to find
the real route cause of the problem.
8D
AKA
8 Decisions
What is it? A formal process tool for solving major
problems from our customers & within the business
What are the Benefits?
• A structured way of thinking about problems and
prevention
• Uses a standard problem solving reporting format
• Fact-based and data-driven
• A team method is used to solve the problem
D1
D2
D3
D4
D5
D6
D7
The NST 8D format
After
Before
Cause Analysis
Team
Machine
Material
5 Why Investigation
D1
Why?
See reverse of sheet for
printed version of causes &
results.
Method
Mother Nature
How Checked
Result
Why?
Countermeasure
What
Measurement
Method
Mother Nature
Who
When
D5/6
Status
Standard
Containment
What
Improve
How Checked
Who
When
D3
Status
M e a s ure m e nt 2 :
Inc o rre c t s ize s s pe c if ie d
o n jigs
Tolerances checked and
found to be incorrect
Y
N
Action
Works order amended
to reflect new tool
Y
N
Measures Affected / % / £ Improvement
Tooling Database
Report. Attached
Y
N
Works order attached
Y
N
Employees Retrained/
Awareness
Y
sizes w ere given the same tolerance as
the rolling process
tolerances w ere not considered, to
allow for the rolling process movement
N
Measurem ent 3: Jigs
not to actual size
required
Jigs checked on CMM and
measure to specified sizes
Good
27/10/2008
New jigs manufactured to accommodate the rolling diameter change.
27/10/2008
Documentation on WIS/CP20 developed w ithin procedures.
WIP checked and verified
I Hindmarsh
28/10/2008
Internal 8D launched
C Gibson
28/10/2008
8D team set-up
D Roberts
29/10/2008
All corruplus jigs checked for similar error (changed w here required)
Operators taken through the findings
100% inspection after plating at pressure test stage
When
Jed Costello 01/06/2007
Colin Gibson 10/11/2008
Danny Roberts 01/06/2007
Danny Roberts 10/11/2008
Colin Gibson 10/11/2008
Colin Gibson 11/11/2008
Follow Up Check & Recognise
Process 1
Process 2
Process 3
Process 4
Press
Circ Weld
Roll
H/T
N
Due to the rolling process which always brings the sizes of the
diameters down from their original size. The welding process
needed to weld the parts to allow for this movement. The actual
welding inspection jigs were specified with the same tolerance as
Who
I Forster
Y
Ro lling o f material will always make the diameters
smaller. (M anufacturing pro cess)
Root Cause
I Hindmarsh
WIS/CP20 Generated
Why?
No Good
Stocks checked and verified
Locate Point Of Effect / Cause
D8
Control
Control
Tooling Database
Updated
D7
Process 4
Result
Good
Countermeasure
What
Works order amended to
reflect new inspection
Y
N
Control
Follow Up Check & Recognise
Process 3
Control
Process 2
Why?
tightened with a torque wrench
O/D Correct
Inspection records changed to reflect new requirement
Process 1
Incorrect sizes w ere specified on the
inspection jigs
Why?
Machine 3: Inadequate Reviewed with engineering and
chuck for holding parts parts are located adequately and
O/D Undersize
Quarantine any further shipments until checked
Locate Point Of Effect / Cause
C irc
we lding
c a us e d
pa rt s t o be
o v e rs ize
o n t he O / D
Why?
Item
Measure
Measure
D3
Status
5 Why Investigation
See reverse of sheet for
printed version of causes &
results.
Why?
Root Cause
When
D4
Rolling process w ill bring the sizes dow n
Problem
Who
Material
D1
Problem Clarification
Qty Returned
5 off D2
On part number AS42703 of batch number 51334 sent in 2004 of an overall
batch qty of 1700 parts. 5 part have been rejected due to the outside
diameter of these parts being undersize. Parts have not been returned for the
QA department to carryout a full di
Standard
Containment
What
Machine
Why?
Item
Problem
Man
Why?
Why?
Measurement
Team
Cause Analysis
Danny Roberts (Production Supervisor) Mark Mullen (Lean Facilitator)
David Beck (Production Operator) Gary Fletcher (Production Team Leader)
D2
Qty Returned
Analyse
Problem Clarification
Problem Description
D0
The outside diameter of these seals measures 15,15mm – 15, 25mm. The
drawing dimension is 15,6mm (Tolerance is +0,0mm to minus 0,25mm).
This non-conformance is causing these seals to fall out of the mating part.
Analyse
Define
Man
D4
Improve
D0
Define
Problem Description
Date: 28/10/08
Ref No: 43
Direct Cause
Work Group Practical Problem Solving / 8D
Date:
Ref No:
Direct Cause
Work Group Practical Problem Solving / 8D
D8
D5/6
Status
D7
D8
These amendments were made during 2007 as part of SFQC (Shop Floor Quality Control) project, when all
jigs were checked before they were given a new location in the new tooling storage area. This was also when
we
first amended
the welding
inspection jigs.
Measures
Affected
/ % / £ Improvement
Subsequent batches since the jig amendments have had no further problems with the Diameters from
either the customer or internally
Works order
attached
Y
N
Inspection Sheet
changed
Y
N
Employees Retrained/
Awareness
Y
N
If you have a major process problem ask the
QA manager to raise an “8D Report”
SPC
AKA
Statistical Process Control
What is it? SPC is a tools which uses data that can
tell you if you are in control of the process you are
doing.
What are the Benefits?
•It can improve product quality by controlling the
process better.
•It can improve productivity by reducing the waste
is producing spoils.
•It allows streamlining of the process by reducing
any issues effecting the control of the process.
Our processes needs to run inside the red lines
Process Control Chart (iX-mR)
Characteristic Length
Xbar = 32.6
UCL= 40.2
44
42
40
38
36
34
32
30
28
26
24
22
_
_
mR bar = 2.56
38
-----
UCL x = Xbar + 2.66 x mRbar
LCL x = Xbar - 2.66 x mRbar
UCL r = 3.267 x mRbar
Sampling Frequency 100%
Specification Limit 30mm +/- 6mm
_
10
9
8
7
6
5
4
3
2
1
0
Date
Time
X
mR
Dept. 019
Chart No two
LCL= 26.7
39
1
36
3
34
2
38
4
CL= 8.38
37
3
40
3
36
4
34
2
32
2
29
3
31
2
28
3
32
4
31
1
27
4
28
1
29
1
32
3
35
3
29
6
30
1
30
0
27
3
Action If you think your process is out of control use SPC
to determine if it is or not?
Takt Time
AKA
Manufacturing drumbeat
What is it? Takt Time is the pace that production needed
to manufacture components to meet our customer demand
What are the Benefits?
• Essentially it provides a pace for the cell to work to.
• It helps our cell operations to run more effectively (in time
with each operation)
• Gives immediate feedback on performance & issues
affecting the performance.
• Takt Boards allow you to see what you need to produce
every hour.
•Targets are set to what every cells can
achieve efficiently &needs to achieve every
hour to meet the customers demands
Action If you have excessive time in the cell then you are
not working to Takt so raise it as a issue.